Quick assembly methods and components for shade structures

Abstract

An umbrella assembly is provided that comprises an umbrella hub comprising an upper portion, a lower portion and a passage configured to be disposed about an umbrella pole. The upper portion includes a top surface that extends between the passage and an outer periphery of the hub. The lower portion includes a bottom surface that extends between the passage and the outer periphery of the hub. The umbrella hub also includes a first engagement position and a second engagement position. The first engagement position is configured to permit insertion of end portions of umbrella structural members into the hub. The first engagement position is provided by first relative movement of the upper and lower portions of the hub along an axis extending through the passage. The second engagement position is configured to retain end portions of umbrella structural members within the hub. The second engagement position is provided by second relative movement of the upper and lower portions of the hub along an axis extending through the passage.

Description

BACKGROUND OF THE INVENTIONS[0001]1. Field of the Invention[0002]This application relates to apparatuses and methods that facilitate efficient assembly of ribs and hubs of umbrellas and other structures with a plurality of elongate structural members that extend from a central hub member.[0003]2. Description of the Related Art[0004]Larger umbrellas, such as market umbrellas, generally include a frame-like structure that is used to support and distribute the weight of an upper portion of the umbrella as well as to enable the umbrella to be opened and closed as desired by the user. The frame-like structure of such umbrellas can take various forms, but often includes one or more hubs connected with a plurality of movable structural members.[0005]Prior art methods of assembly of umbrella hubs and ribs are labor intensive. The process involves inserting a pin through an end portion of each rib of a set of ribs, positioning all of the rib ends in a lower portion of a hub, and then placing...

AI Technical Summary

Benefits of technology

[0006]It would be beneficial to provide structures that enable quicker and less labor intensive assembly of umbrella assemblies, e.g., rib and hub assemblies. An aspect of at least one of the embodiments disclosed herein is the realization that connection devices used in the assembly of shade structures, such as pavilions and outdoor umbrellas, can be improved to provide a more secure, quicker, and more reliable connection. Such devices can be advantageously configured with fewer parts, making them easier to manufacture than devices in the prior art. Such improved connection devices can be particularly advantageous for large shade structures.

[0007]Another aspect of at least one embodiment disclosed herein is the realization that prior art umbrella hubs or hub assemblies include an excessive amount of individual components. For example, individual pins are often individually placed into a portion of the hub before portions of the hub are carefully assembled. This tedious manufacturing can be costly and frustrating. Therefore, embodiments disclosed herein seek to remedy this deficiency by providing a hub assembly that uses a reduced number of parts. Accordingly, the time and cost required for manufacturing the hub can be greatly decreased.

[0013]Various embodiments can broadly encompass an umbrella hub with a plurality of assembly position, which can retain multiple portions of the umbrella hub engaged together for assembly purposes. For example, the portions can be held close together but with a gap permitting pivot member of ribs to be advanced through a gap between the portions. This facilitates assembly because the ends of the ribs will be at least partially retained. Also, the portions of the hub can retain their relative position without the assembler having to hold them together in an assembly position. Thereafter, the hub can be fully coupled in another position, which may be referred to as a fully assembled or a locked position. In this position, the rib ends (and pivots disposed therein) can be held securely enough to withstand normal operational loads and a full duty cycle.

[0014]In other broad aspects, hub assembly includes novel locking components that facilitate snap-together assembly of the hub. The locking components can include mating protrusions and recesses. The locking components can include one or more tapered posts that can project across an interface zone between multiple, e.g., two hub components. One or more tapered recesses can be provided to receive the tapered posts. Deflection of one or both of the posts and recesses can enable positioning of the tapered post in the recesses to provide locking of the hub portions. In one arrangement, deflection of the recess can be enabled by one or more slits or other structure enhancing the deformation in or deformability of a wall adjacent to the recess. In certain cases, the tapered posts and recesses provide a robust connection between hub components in at least one of a partially and fully assembled configuration.

Problems solved by technology

This tedious manufacturing can be costly and frustrating.

Another aspect of at least one of the embodiments disclosed herein is the realization that while some devices have been suggested to expedite assembly, such devices have been inadequate, for example lacking the ability to bear a full range of operational loads, which can be much higher than the weight of the components of the shade structure, particularly in windy conditions.

Images